Mounting element and method for a loosely laid synthetic resin film and roof construction containing same

ABSTRACT

A mounting element for synthetic resin films loosely laid on a layer of thermal insulating material for heat-insulated roof construction which are ungraveled comprising, as seen in cross section, a T-shaped element, a mounting flange unilaterally arranged at the base of the T at right angles, and a bottom supporting structure joined to the mounting flange of the Tshaped element, said mounting element being adaptable to provide a composite structural component having heat and insulating material foamed thereon.

United States Patent 1191 Haage 1451 Feb. 18,1975

[ 1 MOUNTING ELEMENT AND METHOD FOR A LOOSELY LAID SYNTHETIC RESIN FILM AND ROOF CONSTRUCTION CONTAINING SAME Inventor:

[75] Karl I-laage, Troisdorf-Spich,

Germany Assignee: Dynamit Nobel Aktiengesellschaft,

Troisdorf, Germany Filed: June 18, 1973 Appl, No.: 370,687

[1.5. CI 52/309, 52/443, 52/450, 52/729, 52/741 [51] Int. Cl. E046 2/50 [58] Field of Search 52/408, 450, 452, 729, 52/309, 443, 618, 453, 449, 446, 447, 615, 340, 378, 622

References Cited UNITED STATES PATENTS 10/1967 Palfey 52/615 3,397,497 8/1968 Shea et al. 52/458 X 3,466,222 9/1969 Curtis 52/309 X 3,472,728 10/1969 Hitch 52/309 X 3,479,779 11/1969 Ziegler 52/309 X 3,484,331 12/1969 Betz 52/309 X 3,732,138 5/1973 Almog 52/615 X Primary Examiner-Frank L. Abbott Assistant ExaminerCarl D. Friedman Attorney, Agent, or Firm-Craig & Antonelli 1 1 ABSTRACT A mounting element for synthetic resin films loosely laid on a layer of thermal insulating material for heatinsulated roof construction which are ungraveled comprising, as seen in cross section, 11 T-shaped element, a mounting flange unilaterally arranged at the base of the T at right angles, and a bottom supporting structure joined to the mounting flange of the T-shaped element, said mounting element being adaptable to provide a composite structural component having heat and insulating material foamed thereon.

22 Claims, 1 Drawing Figure MOUNTING ELEMENT AND METHOD FOR A LOOSELY LAID SYNTHETIC RESIN FILM AND ROOF CONSTRUCTION CONTAINING SAME This invention relates to an improvement in the mounting element for synthetic resin films loosely laid on abutting panels, e. g., thermal insulating panels for heat-insulated roof constructions which are not graveled (described in German Pat. application No. P 22 29 423.1), which mounting element is characterized in that the mounting element, as seen in cross section, has a T-shaped panel securing means or element and has a mounting flange unilaterally arranged at the base of the T at a right angle and to a prefabricated roof covering unit formed with the improved mounting element.

In the arrangement disclosed in the above-identified German applicationthe roof sheathing is generally attached to the mounting flange of the T-shaped element by cementing or with the use of high-temperature or solution welding. The mounting element achieves advantages by a secure fastening of the roof sheathing at desired intervals, and by a rapid installation of the roof. However, the use of the mounting element is limited to incorporation into heat-insulated roofs, which are built up on the roof.

Therefore, it is an object of the present invention to construct the insulation of a heat-insulated roof, with the use of the mounting element proposed in the German application, so that the assembly of the heatinsulated roof, as well as the roof sheathing, is simplified.

According to the invention, it is suggested to construct the above-described mounting element in such a manner that the mounting element is joined to a bottom structure of the roof to form a composite building component with heat insulation being foamed thereon.

The heat insulation is foamed onto the bottom structure up to about the upper edge of the T-shaped element member, so that the uppersurface of the T- profile member remains uncovered by the foamed heat insulation.

The mounting element is incorporated during the manufacturing process in the production of a prefabricated, self-supporting roof covering unit provided with foamed heat insulation, and thus is a composite building component of the unit. The mounting element can be bonded to thebottom structure by the adhesive strength and shear strength of the foam.

In order to improve the bond of the mounting element in the foam, the mounting element can be provided with perforations and/or with additional profiling in the area of the contact surface with the foam.

The curing of the foam, preferably polyurethane foam, which takes place after the application of the mounting element by placing a foamable material on the bottom structure and foaming this material, has the effect that essentially all parts of the mounting element are firmly surrounded by the thus-formed plastic foam and are secured against displacement thereby; the foam only leaves the upper connecting flange vacant or uncovered.

Thus, the invention provides a prefabricated roof covering unit consisting of a bottom structure, a heat insulation, and a mounting element for the roof sheathing, having substantial advantages, residing in that the prefabrication can be more accurately controlled, the components of the heat-insulated roof are joined to- 2 gether more advantageously, and the insulating characteristics of the heat insulation can be preselected by the thickness, type, pore size, etc., of the foam material.

The roof covering unit is prefabricated as a largearea element of the heat insulated roof as a composite part and installed on the roof structure as a unitary structure.

The position ofthe mounting element is fixed without having to execute time-consuming measuring operations on the roof. Also, the roof can be rapidly assembled from the prefabricated components.

The commercially available roofing panels can be used as the roof sheathing by a suitable selection of the spacings of the mounting elements from one another, thus reducing the number of connection seams as compared to elements where the roof sheathing is applied during the prefabrication. I

It is also possible to form the mounting flange of the mounting element on both sides of the T-shaped portion.

The mounting element, as further described in the German application heretofore noted, can consist of one or several parts, so that several heights of the mounting element can be chosen by the insertion of the thickened portions of the web of the T-shaped element into the mounting flange depending on which foam height is intended.

However, for purposes of the foamed roof structure, one-part or integral mounting elements are preferred.

In case of an appropriate foam quality with regard to shear strength and adhesive strength at the contact surfaces, the mounting element can be constructed so that recesses in the web or the T-shaped element and/or additional profiling in the foam-bonding zones of the mounting element, result in such a strong bonding effect that the mounting element need not be fastened to the bottom structure. The selection of, for example, trapezoidal sheets with undercut portions for the bottom structure likewise results in an improved bonding effect.

The mounting element consists advantageously of a synthetic resin of the same or a similar type as the synthetic resin film used as the roof sheathing, or it is coated with such a material.

As the bottom structure for the heat-insulated roof structure, it is possible to use any desired materials which are load-bearing and preferably lightweight. Advantageously, these materials are profiled metal sheets, especially metal sheet elements having a trapezoidal cross section, or also correspondingly profiled structural components made from reinforced synthetic resins, especially resins provided with glass fiber reinforcing inserts or similar features.

It is possible to provide a separating layer between the heat insulation and the roof sheathing, for example an additionally insulating or flame propagationretarding, large-area layer consisting of, for example, glass fiber mats, asbestos fiber panels, or similar materials. This separating layer can optionally be installed after applying the foamable material, prior to the foaming step, and can thereby serve as an upper mold wall during the foaming of the heat insulation, which wall remains permanently in the roof structure. I

The foam will be produced generally in the plant, an in special cases, for example when building a large series of structures, at the building site.

During the manufacture ofthe roof elements, the spacing of the mounting elements is determined so that, for example, about 500 mm. is provided in the marginal area, and about 1000 mm. in the extension of the roof area'so that the roof seal is not overstressed, depending on the force exerted by wind suction and other effects.

The mounting elements can be attached to the bottom structure by means of rivets, blind rivets, screws, or similar parts, or by cementing, welding, and the like.

The spacing of the mounting element at the mounting flange is dependent on the construction and quality of the synthetic foam material, since the adhesion within the foam is a contributory factor in the transmission of the wind suction forces into construction. In borderline cases, it is possible to omit any fastening to the bottom structure, for example in the above described flush anchoring of the foam of the heat insulation.

ln.the drawing, the figure shows a heat-insulated roof construction with heat insulation produced by foaming a synthetic foam material on a profiled bottom struc- .ture, with the material essentially surrounding the mounting element, and with a separating layer applied thereon and a superimposed, loosely laid roof sheathing of synthetic resin film such as a PVC film.

As shown, la denotes the uncovered connecting flange and lb denotes the mounting flange of the mounting element 2 which is T-shaped in cross section. The mounting element is made ofa soft PVC or an elastomer such as butyl rubber. The foamed heat insulation 3 is made of polystyrene, polyurethane or phenol resin foam and is limited on the topside by a separating layer 5 made of, for example, glass fiber mat and provided in this example and disposed underneath the connecting flange, and on the bottom side, the insulation is foamed flush into the profile of a trapezoidal sheet 6 which forms the bottom structure of the roof construction. The loosely laid roof sheathing 4 of film webs is welded watertight to the mounting element by solution welding at 7.

While the novel embodiments of the invention have been described, it will be understood that various omissions, modifications and changes in these embodiments may be made by one skilled in the art without departing from the spirit and scope of the invention.

What is claimed is:

l.A mounting apparatus for synthetic resin films loosely laid on a layer of thermal insulating material for heat-insulated roof construction which are ungraveled comprising, as seen in cross section, a T-shaped element, a mounting flange unilaterally arranged at the base of the T at right angles, a bottom structure joined to and supporting the mounting flange of the T-shaped element, and heat insulation foamed onto the bottom structure and onto said flange and T-shaped element so that the upper surface of the T-shaped element remains uncovered by insulation whereby the uncovered upper surface of the T-shaped element provides a broad surface to which a loosely laid roof sheathing can be bonded.

2. The apparatus of claim 1, in which said mounting element further comprises at least one of perforations and additional surfaces in the zone of contact with said foam for improving the bond therebetween.

3. The mounting apparatus of claim l, in which T- shaped element and the mounting flange are coated with a synthetic resin of the same or of a similar kind as the synthetic resin film.

4. The mounting apparatus of claim 1, in which said apparatus is provided with perforations in the zone of contact with the foam for improving the bond therebetween.

5. The mounting apparatus of claim 1, in which the heat insulation is foamed up to about the upper edge of the T-shaped element.

6. The mounting apparatus of claim 5, in which a separating layer of material is provided between the heatinsulation foam and the synthetic resin film.

7. The mounting apparatus of claim 5, in which a plurality of T-shaped elements are provided to form spaces therebetween and in which said heat-insulation is foamed to substantially fill the spaces.

8. A prefabricated self-supporting roof covering unit which comprises a mounting element having a T- shaped element and a mounting flange arranged at the base of said T-shaped element at right angles thereto, a bottom structure positioned below and supporting said mounting flange, heat-insulating material foamed on said bottom structure and on at least a portion of the surface of said mounting element so that an upper exposed surface of the T-shaped element remains, and a roof sheathing of snythetic resin film loosely laid on the upper exposed surface of the T-shaped element and bonded thereto.

9. The roof covering unit of claim 8, in which the mounting element is bonded to the bottom supporting structure by adhesive strength and shear strength of the heat-insulating foam.

10. The roof covering unit of claim 8, in which said mounting element is provided with at least one of perforations and additional surfaces in the zone of the contact with said foam for improving the bond therebe tween.

11. The roof covering unit of claim 10, in which said bottom supporting structure comprises shaped metal sheets having corrugated-like recesses therein for re ceiving said heat-insulating foam.

12. The roof covering unit of claim 11, in which said bottom supporting structure comprises rigid sheets having a trapezoidal cross section.

13. The roof covering unit of claim 8, in which a separating layer of material is provided between the heat insulating foam and the synthetic resin film, said separating layer providing an upper surface of a mold cavity to facilitate formation of said heat-insulating foam, the bottom surface of said mold cavity being formed by said bottom supporting structure.

14. The roof covering unit of claim 8, in which the heat insulation is foamed up to about the upper edge of the T-shaped element.

15. The roof covering unit of'claim 14, in which a separating layer of material is provided on said insulating material.

16. The roof covering unit fo claim 15, in which the mounting element is bonded to the bottom supporting structure by adhesive strength and shear strength of the heat-insulating foam, in which said mounting element is provided with perforations in the zone of the contact with said foam for improving the bond therebetween, and in which said bottom supporting structure comprises shaped metal sheets having corrugated-like recesses therein for receiving said heat-insulating foam.

17. The mounting element of claim 15, in which a mounting flange is formed on both sides of said T- shaped apparatus.

5 6 18. The mounting apparatus of claim 17, in which supporting roof covering unit comprising: said bottom supporting structure comprises shaped supporting a plurality of T-shaped mounting elemetal sheets having recesses therein for containing said m on a bottom supporting structure h a heatmsulatmg mounting flange arranged at the base of each T- 19. The mounting apparatus of claim 18, m which shaped element at right angles theretoy said T-shaped element and the mounting flange are a l in a foamable material to said su ortin formed of a synthetic resin of the same or of a similar pp y g pp g kind as the synthetic resin film. smicture 20. The roof covering unit of claim 8, wherein the applying a separatmg layer matenal to sand foamable material,

roof sheathing is outermost.

The roof covering of Claim 8, in which a plurality foaming said foamable material to cover at least a of T-shaped elements are provided to form spaces Portion Ofsaid P elements Wherebythe ptherebetween, and in which said heat insulating matearming layer Serves a an upper mold Wall during rial is foamed to substantially fill the spaces. the foaming of the material.

22. A method for making a prefabricated self- 

1. A mounting apparatus for synthetic resin films loosely laid on a layer of thermal insulating material for heat-insulated roof construction which are ungraveled comprising, as seen in cross section, a T-shaped element, a mounting flange unilaterally arranged at the base of the T at right angles, a bottom structure joined to and supporting the mounting flange of the T-shaped element, and heat insulation foamed onto the bottom structure and onto said flange and T-shaped element so that the upper surface of the T-shaped element remains uncovered by insulation whereby the uncovered upper surface of the T-shaped element provides a broad surface to which a loosely laid roof sheathing can be bonded.
 2. The apparatus of claim 1, in which said mounting element further comprises at least one of perforations and additional surfaces in the zone of contact with said foam for improving the bond therebetween.
 3. The mounting apparatus of claim 1, in which T-shaped element and the mounting flange are coated with a synthetic resin of the same or of a similar kind as the synthetic resin film.
 4. The mounting apparatus of claim 1, in which said apparatus is provided with perforations in the zone of contact with the foam for improving the bond therebetween.
 5. The mounting apparatus of claim 1, in which the heat insulation is foamed up to about the upper edge of the T-shaped element.
 6. The mounting apparatus of claim 5, in which a separating layer of material is provided between the heat-insulation foam and the synthetic resin film.
 7. The mounting apparatus of claim 5, in which a plurality of T-shaped elements are provided to form spaces therebetween and in which said heat-insulation is foamed to substantially fill the spaces.
 8. A prefabricated self-supporting roof covering unit which compriSes a mounting element having a T-shaped element and a mounting flange arranged at the base of said T-shaped element at right angles thereto, a bottom structure positioned below and supporting said mounting flange, heat-insulating material foamed on said bottom structure and on at least a portion of the surface of said mounting element so that an upper exposed surface of the T-shaped element remains, and a roof sheathing of snythetic resin film loosely laid on the upper exposed surface of the T-shaped element and bonded thereto.
 9. The roof covering unit of claim 8, in which the mounting element is bonded to the bottom supporting structure by adhesive strength and shear strength of the heat-insulating foam.
 10. The roof covering unit of claim 8, in which said mounting element is provided with at least one of perforations and additional surfaces in the zone of the contact with said foam for improving the bond therebetween.
 11. The roof covering unit of claim 10, in which said bottom supporting structure comprises shaped metal sheets having corrugated-like recesses therein for receiving said heat-insulating foam.
 12. The roof covering unit of claim 11, in which said bottom supporting structure comprises rigid sheets having a trapezoidal cross section.
 13. The roof covering unit of claim 8, in which a separating layer of material is provided between the heat-insulating foam and the synthetic resin film, said separating layer providing an upper surface of a mold cavity to facilitate formation of said heat-insulating foam, the bottom surface of said mold cavity being formed by said bottom supporting structure.
 14. The roof covering unit of claim 8, in which the heat insulation is foamed up to about the upper edge of the T-shaped element.
 15. The roof covering unit of claim 14, in which a separating layer of material is provided on said insulating material.
 16. The roof covering unit fo claim 15, in which the mounting element is bonded to the bottom supporting structure by adhesive strength and shear strength of the heat-insulating foam, in which said mounting element is provided with perforations in the zone of the contact with said foam for improving the bond therebetween, and in which said bottom supporting structure comprises shaped metal sheets having corrugated-like recesses therein for receiving said heat-insulating foam.
 17. The mounting element of claim 15, in which a mounting flange is formed on both sides of said T-shaped apparatus.
 18. The mounting apparatus of claim 17, in which said bottom supporting structure comprises shaped metal sheets having recesses therein for containing said heat-insulating foam.
 19. The mounting apparatus of claim 18, in which said T-shaped element and the mounting flange are formed of a synthetic resin of the same or of a similar kind as the synthetic resin film.
 20. The roof covering unit of claim 8, wherein the roof sheathing is outermost.
 21. The roof covering of claim 8, in which a plurality of T-shaped elements are provided to form spaces therebetween, and in which said heat insulating material is foamed to substantially fill the spaces.
 22. A method for making a prefabricated self-supporting roof covering unit comprising: supporting a plurality of T-shaped mounting elements on a bottom supporting structure with a mounting flange arranged at the base of each T-shaped element at right angles thereto, applying a foamable material to said supporting structure, applying a separating layer material to said foamable material, foaming said foamable material to cover at least a portion of said T-shaped elements whereby the separating layer serves as an upper mold wall during the foaming of the material. 